Volvo Coupes/Sedans/Wagons 1970-1989 Repair Guide

Manual Steering Gear

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See Figures 1 and 2



Click image to see an enlarged view

Fig. Fig. 1: Cutaway view of Volvo's manual rack and pinion steering gear



Click image to see an enlarged view

Fig. Fig. 2: Troubleshooting the Manual Steering Gear

REMOVAL & INSTALLATION



140 and 1800 Series; 164 Models
  1. Jack up the front end of the vehicle and support on jackstands.
  2.  
  3. Release the bolt at the lower steering coupling flange. Remove the nuts and push the lower part of the flange as far down as possible on the guide bolt.
  4.  
  5. Remove the locknut for the Pitman arm. Matchmark the arm and the shaft for ease of reassembly. Pull off the Pitman arm with a Pitman arm puller (Volvo tool 2370 or equivalent). When the puller has been set in place, turn the wheels completely to the left.
  6.  
  7. Remove the nuts and bolts and lift off the steering gearbox.
  8.  

To install:
  1. Make sure the steering gearbox is in its centered position. (Alternate position is full left.) Reinstall the steering gear in position and secure the mounting bolts.
  2.  
  3. Set the wheels so they match the setting of the steering gearbox, i.e. centered or full left, and place the steering wheel in the same position. Secure both halves of the lower flange. Check that the flange splines coincide with the shaft splines.
  4.  
  5. Install the Pitman arm to the steering gearbox. If the steering gear and Pitman arm are matchmarked, make sure the marks align and reinstall the arm. If the gear and arm are not marked, follow the procedure below:
    1. Turn the steering wheel fully to the left.
    2.  
    3. Turn the steering wheel fully to the right (until it binds) and count the number of turns the wheel makes from left lock to right lock. Measure the turns carefully and approximate any fractional turns ( 1 / 2 , 1 / 4 , etc).
    4.  
    5. Beginning at right lock, return the wheel one half of the number of turns it took to get there. This will put the steering gear box at its centered position.
    6.  
    7. Set the left wheel straight ahead.
    8.  
    9. Connect the Pitman arm to the steering box.
    10.  
    11. Lower the car to the ground and check that the wheels are straight ahead. If it is necessary to adjust the wheels, remember to use the correct tool when removing the Pitman arm from the shaft.
    12.  

  6.  
  7. Tighten the Pitman arm bolt to 110 ft. lbs. (149 Nm).
  8.  
  9. Lower the car to the ground and road test for proper steering alignment.
  10.  

200 Series

See Figure 3

  1. Remove the lock bolt and nut from the column flange. Bend apart the flange slightly with a prybar.
  2.  
  3. Jack up the front end. The stands should be positioned at the jack supports. Remove the front wheels.
  4.  
  5. Disconnect the tie rod ends, using a ball joint puller.
  6.  



Click image to see an enlarged view

Fig. Fig. 3: Cutaway view of the manual steering components-240, 260 series and 1980 and later models

  1. Remove the splash guard.
  2.  
  3. Disconnect the steering gear from the front axle member (beam).
  4.  

  1. Disconnect the steering gear at the steering shaft flange. Remove the steering gear. Save the dowel pins.
  2.  

To install:
  1. Install rubber spacers and plates for the steering gear attachment points.
  2.  
  3. Position the steering gear and guide the pinion shaft into the steering shaft. The recess on the pinion shaft should be aligned towards the lock bolt opening in the shaft.
  4.  
  5. Attach the steering gear to the front axle member. Check that the U-bolts are aligned in the plate slots. Install flat washers and nuts. Tighten the nuts to 10-18 ft. lbs. (14-24 Nm).
  6.  
  7. Install the splash guard.
  8.  
  9. Connect the steering rods to the steering arms. Tighten the nuts to 44 ft. lbs. (60 Nm).
  10.  
  11. Install the front wheels and lower the vehicle.
  12.  
  13. Install the lock bolt for the steering shaft flange. Tighten the bolt to 18 ft. lbs. (24 Nm).
  14.  
  15. Have the alignment checked and reset if needed.
  16.  

 
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